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New UPS Batteries –Keep up so you

can keep on backin’-up

Dan Lambert

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Data Center World – Certified Vendor Neutral

Each presenter is required to certify that their presentation will be vendor-neutral.

As an attendee you have a right to enforce this policy of having no sales pitch within a session by alerting the speaker if you feel the session is not being presented in a vendor neutral fashion. If the issue continues to be a problem, please alert Data Center World staff after the session is complete.

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Batteries – Keep up so you can keep on backin’ up

New back-up battery chemistries are driving a shift in the market because of desirable new capabilities. But how do you safely and reliably deploy for best outcomes? UPS users need to understand the battery standards and practices in order to make decisions on where, when and how to deploy these different battery chemistries. Standards for recommended practices are changing even for traditional battery chemistries and additional standards are being developed for the new chemistries. This presentation will give users the knowledge they need about current and new battery chemistry standards that guide best practices in the use of stationary batteries. Battery chemistries covered include lead-acid, lithium-ion and nickel-zinc. The good news is that industry and standards organizations are staying on top of the sea-change in stationary battery chemistries. Recommended best practices and the standards behind them from the IEEE, UL and NFPA will be covered.


UPS Technology

UL 1778 – Uninterruptible Power Systems

Lithium Energy Storage System

Lithium-ion Battery Cabinet


12V TPPL

Lead-Acid Battery Cabinet


Nickel-Zinc Monobloc

Nickel-zinc Battery Cabinet


Chemistry Basics

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Lithium-ion Chemistry BasicsMaterialsCarbonMetal oxideLithium Salt

Discharge LiC6 + CoO2

ChargeC6 + LiCoO2

• An alkaline battery chemistry using abundant materials • High energy density, no memory effect, and low self-discharge• 1/3 the weight of lead-acid

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Lead-Acid Chemistry BasicsMaterialsLead & Lead dioxideSulfuric acidElectrolyte

Discharge PbO2 + H2SO4 + PbChargePbS04 + 2H2O + PBSO4 + Energy

• Primarily two types of Advanced Pba, Thin Plate Pure Lead (TPPL) and Lead-Carbon

• Very low energy-to-weight ratio, low energy-to-volume ratio, large power-to-weight ratio

• Relatively short service life

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Nickel-Zinc Chemistry Basics MaterialsCathode – Ni HydroxideAnode – Zn OxideElectrolyte – Potassium Hydroxide

Discharge Cathode: 2NiOOH + 2H2O + 2e- → 2Ni(OH)2 + 2OH- 0.49 VAnode: Zn + 2OH- → Zn(OH)2 + 2 e- -1.24 VOverall: 2NiOOH + 2H2O + Zn → 2Ni(OH)2 + Zn(OH)2 1.73 V ChargeOverall: 2Ni(OH)2 + Zn(OH)2 → 2NiOOH + 2H2O + Zn

• An alkaline battery chemistry using abundant materials• Eliminating the Metal hydride electrode and replacing with zinc gains 400mV• Zinc electrode design and management is key to long cycle life

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Power vs. Energy

Sources: (1) Battery University; http://batteryuniversity.com/learn/article/types_of_lithium_ion; (2) EPEC, http://www.epectec.com/batteries/cell-comparison.html(3) ZincFive, Inc., www.zincfive.com for NiZn data

POWER ENERGY

Nickel-Zinc Lead-AcidAGM

Lithium Titanate (Li4Ti5O12)

LTO

(2) Lithium Iron Phosphate(LiFePO4)

Power Cell

(1) Lithium Iron Phosphate(LiFePO4)

Energy Cell

Lithium Manganese Oxide

(LiMn2O4)

Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO2

or NMC)

Lithium Cobalt Oxide(LiCoO2)

Lithium Nickel Cobalt Aluminum

Oxide (LiNiCoAlO2)

Voltage (volts) 1.65 2.0 2.40 3.20 3.20 3.70 3.60 3.60 3.60

Specific Energy Density (Wh/Kg) 80-100 30-50 65-75 90–120 120-160 100–130 150–220 150–200 200-275

Specific Power (25C,2.4 mins) (Watts/Kg) 2,000-2,500 500-700 700-800 2,000-2,500 120-160 100-130 150-220 150-200 200-300

Charge Rate (C) 10.0 C/8 5.0 1.0 1.0 1.0 0.7–1.0 0.7–1.0 0.7

Discharge Rate (C) 25.0 1.0 10.0 5.0-6.0 1.0 0.7–1.0 1.0-6.0 1.0 1.0

Self Discharge Rate (%/mo.) 1-2% 5% 5% 5% 5% 5% 5% 5% 5%

Cycle Life (#) 600-1,200 200-400 5,000–15,000 1000–2000 1000–2000 300–700 1,000–2,000 500–1,000 500

Safety Risk/ImpactThermal Runaway (°C)

Low (H2)None

Low-MedNone

Low275°

High250°

Moderate250°

Moderate250°

Moderate150°

Moderate150°

Moderate150°

AC Impedance (mΩ) 1.8-2.2 3-4 1-2 25 50 50 75 200 200

Charge Time (Hours) 1-2 8-16 1-2 1-3 >2 >2 >2 >2 >2

ApplicationsUPS, hybrid

powertrain, starter battery

Auto SLI,UPS, Stationary

Industrial,Military

UPS, electric powertrain (Mitsubishi i-MiEV, Honda Fit EV)

Portable and stationary needing high load

currents and endurance

Power tools, medical devices, electric

powertrains

Power tools, medical devices, electric

powertrains

E-bikes, medical devices, EVs,

industrial

Mobile phones, etablets, laptops,

cameras

Industrial, electric powertrain (Tesla)

Cost @ High Vol. Pack Levl ($/KwH) $350-400 $250-300 $650-750 $450-550 $175-250 $350-400 $200-250 $300-350 $250-350

http://batteryuniversity.com/learn/article/types_of_lithium_ion

http://www.epectec.com/batteries/cell-comparison.html


Charge and Discharge Performance

Lithium-ion Charge

Lithium-ion Discharge

Lead-Acid Charge

Lead-Acid Discharge

Coup de Fouet

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Nickel-Zinc Charge

C/4 Charge @25C – 80AH 13.2V Monobloc

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Nickel-Zinc Discharge

5 minute 250kW Discharge @25C – 80AH, 13.2V Monobloc


Battery Safety

Lithium-ion Battery Safety

• Lithium solutions offering higher power capability, but have higher volatility potential.

• Lithium battery systems must incorporate full cell-by-cell management to prevent undercharge, overcharge, and to prevent thermal runaway.

• The management system may disable the entire string due to a fault in one cell.

• Lithium products offer improved temperature tolerance than typical lead-acid, but life and performance are affected by elevated temperatures.

Lithium-ion Battery Safety

• Manufacturers of lithium solutions recommend various fire suppression methods, including water (conventional sprinkler system) and FM200 gas.

• In the event there is a thermal runaway event, there is risk of exposure to toxic gases and flame, besides the electrical hazards involved.

• Recent offers have improved safety, however, there are many Authorities Having Jurisdiction (AHJ) that severely restrict all lithium installations.

• Lithium batteries used in stationary applications must be shipped by surface carrier due to UN transportation directives.

Lead-Acid Battery Safety

• Lead-acid batteries utilize an electrolyte solution of sulfuric acid (H2SO4) and water. The liquid and gases can creep through seals and cause corrosion of the terminal posts and connectors.

• Battery monitoring is strongly recommended due to the fact that one cell failing can disable the entire string. Cells tend to fail in an “open”, non-conductive state.

• Lead-acid batteries provide their best life vs. capacity at 25°C (77 °F). Newer technologies promise improved life at higher temperatures.

Lead-Acid Battery Safety

• In the event there is a thermal runaway event, there is risk of exposure to toxic gases and flame, besides the electrical hazards involved.

• Many AHJs require spill containment despite the fact that the battery is listed as “non-spillable” due to concerns about sulfuric acid.

• Lead, a highly toxic metal is the primary ingredient in both positive and negative electrodes.

Nickel-Zinc Battery Safety

• Nickel-Zinc (Ni-Zn) batteries utilize an electrolyte solution of potassium hydroxide (KOH) and water (similar to the Drano product).

• Most commercially available Ni-Zn batteries are non-spillable prismatic cells in a conventional monobloc container.

• Simple battery monitoring is recommended, but is not essential for safety. Cells fail as a low impedance conductor, allowing the string to continue operating.

Nickel-Zinc Battery Safety

• Ni-Zn batteries have a broad temperature tolerance without significant loss of capacity.

• There is very little potential for a thermal runaway however, there is risk of exposure to the electrical hazards involved with operating any equivalent battery.

• The primary metals used in typical Ni-Zn batteries are nickel, zinc, and copper. All of these are commonly used in metallurgy.


Standards

IEEE Standards

• IEEE 1184 Guide for Batteries for Uninterruptible Power Supply Systems• IEEE 1187 Recommended Practice for Installation Design and Installation of

Valve-Regulated Lead-Acid Batteries for Stationary Applications • IEEE 1188 Recommended Practice for Maintenance, Testing, and

Replacement of Valve-Regulated Lead- Acid (VRLA) Batteries for Stationary Applications

• IEEE 1679 Recommended Practice for the Characterization and Evaluation of Emerging Energy Storage Technologies in Stationary Applications

• New document underway for Nickel-Zinc in the IEEE 1679 document family.• Sizing documents for lithium are too chemistry dependent to write a

comprehensive document at this time.• Sizing for nickel-zinc is similar to nickel-cadmium, so IEEE documents related

to Ni-Cd are applicable to Ni-Zn in the near term.

UL Standards

• All battery systems in cabinets used with a UPS must meet UL 1778 • UL 1973 Standard for Batteries for Use in Stationary, Vehicle Auxiliary

Power and Light Electric Rail (LER) Applications• UL 1989 Standard for Standby Batteries• UL 9540 Standard for Energy Storage Systems and Equipment• UL 9540A Test Method for Evaluating Thermal Runaway Fire Propagation in

Battery Energy Storage Systems

TPPL and Ni-Zn are listed under UL 1989, comparing them favorably to existing VRLA batteries that are ubiquitous in the marketplace.Ni-Zn and some TPPL have already been tested to UL 1973, Section 19, for imbalance performance, and have passed.UL 9540 is a test sequence that is coming into more prominence, and the flammability testing is somewhat onerous, at least in concept.

NFPA and International Standards• NFPA 1 Fire Code• NFPA 101 Life Safety Code®• NFPA 111 Standard on Stored Electrical Energy Emergency and Standby Power Systems• NFPA 855 Standard for the Installation of Stationary Energy Storage Systems• International Fire Code (IFC)• International Building Code (IBC)

These codes are already generally incorporated into the existing building and electrical codes in the US.

NFPA 855 Second Draft Report has just been released. NFPA 855 is not approved yet, but has the potential to be a major disruption to advanced energy storage implementation if it is approved in the current form.If you, or anyone you know, is an NFPA member, they need to review 855 and make their opinions heard.


Recycling

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UPS Battery Chemistry Recycling

• Highly recyclable • Lead-free. All Zinc, Copper,

Nickel recaptured and saleable on commodity market

• No air freight restrictions

• Highly recyclable

• World's worst pollution problem**

• 120M people worldwide lead poisoned*

• 50% of materials are recoverable

• Expensive recovery effort

• Hazardous materials with air freight restrictions

Li-Ion Lead-Acid NiZn

*Fewtrell L, Kaufmann R, Prüss-Üstün A. Lead: assessing the environmental burden of disease at national and local level. Geneva, World Health Organization, 2003 (WHO Environmental Burden of Disease Series, No. 2).; http:// www.who.int/quantifying_ehimpacts/publications/en/leadebd2.pdf**Pure Earth/Green Cross 11th annual 2016 report, “World’s Worst Pollution Problems” http://www.worstpolluted.org/;

>90%90%50%


Tradeoffs when making UPS battery deployment decisions

Lithium-ion UPS TradeoffsPositives –

• Long life

• Good TCO

• Less floor space required

• Lighter than lead options

Negatives –

• Shipping restrictions

• Lack of acceptance by AHJs.

• Limited acceptance by data center operators.

Lead-Acid UPS TradeoffsPositives –• Long history with lead technologies• Least expensive first cost option• Safety aspects are well understood• AvailabilityNegatives –• Lowest power density option• Relatively short service life• Can fail unexpectedly• Risk of thermal runaway unless monitored closely• Lowest ROI of available options

Nickel-Zinc UPS TradeoffsPositives –

• Long life

• Good power density

• Broad temperature range

• No thermal runaway risk

Negatives –

• Not well known in the market

• UPS manufacturers are just starting acceptance testing

• Relatively few commercially available products

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3 Key Things You Have Learned During this Session

1) Understand how to apply and utilize lead-acid, lithium-ion and nickel-zinc batteries in UPS deployments according to recommendations and best practices from the IEEE, UL and NFPA.

2) Develop a working knowledge of battery chemistry options for data center UPS solutions.

3) Understand the tradeoffs when making UPS battery deployment decisions.

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Thank you

Dan Lambert, ZincFiveProduct Manager – Data Center Solutions

[email protected]

www.zincfive.com/contact/

Twitter: @datacenterworld

mailto:[email protected]

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